JP6526258B2 - System and method for preparation and application of non-portland cementitious materials - Google Patents

Description

This application claims priority to US Patent Application No. 14 / 705,534, filed May 6, 2015, to the US Patent and Trademark Office. The entire disclosure of this disclosure is incorporated herein by reference.

  The present disclosure relates to construction materials, and more particularly, to methods of making and applying construction materials.

  Existing methods in the field of sewer repair and concrete repair and construction may include the application of shotcrete that is projected pneumatically to the surface that needs repair or construction. The shotcrete comprises the materials contained in the base concrete, such as sand, portland cement and liquid. At a particular worksite, the shotcrete may be in the form of either dry or wet mixing. The term "dry mixing" generally refers to pneumatically moving some or all of the material in a dry state through a hose to a nozzle where the operator controls the addition of liquid to the dry mixture. , And then, projecting the mixed substance. Conversely, the term "wet mixing" generally involves moving the premixed liquid-containing concrete through a hose prior to projection.

Several companies have tried to change the material composition of the shotcrete to gain some benefit. Thus, some methods may involve the use of geopolymers. However, these materials are often susceptible to corrosion due to the organic materials inherent in these products. For example, Milliken (Milliken) Corporation (R), a variety of products are manufactured in line of GeoSpray ^TM and GeoSpray ^TM AMS. AMS product can be used as before GeoSpray ^TM product processing and / or post-treatment products. GeoSpray is a Portland cement-based and contains a very small proportion of geopolymers. This mixture is not acid stable. AMS contains the effect of acid on Portland cement concrete and organics that are effective against microbial induced corrosion that occurs in Portland cement materials.

  In a first embodiment, a method is provided for applying a building material. The method may include mixing blast furnace slag material, geopolymer material, alkaline powder, and sand in a batching and mixing apparatus to produce non-portland cementitious material. Also, the method transfers the non-Portland cement based material from the batching and mixing device through a conduit to a nozzle, and combines the transferred non-Portland cement based material with a liquid at the nozzle It may also include the step of producing a partially liquefied non-Portland cement based material. In addition, the method may also include the step of applying the partially liquefied non-Portland cement based material to a surface using air pressure.

One or more of the following features may be included. In some embodiments, the geopolymer material is at least one of volcanic rock and pumice. The alkaline powder may include silicate. The step of mixing may be performed as dry mixing. The non-Portland cement based material may be inorganic. The mixing may be performed on a mobile batching and mixing vehicle. The non-Portland cement based material may include at least one of clay, gneiss, granite, quartz trachyte, andesite, piclite, potassium feldspar, albite, pumice, or zeolite. The mixing may include mixing with a portable gun configured to receive the non-Portland cement-based material from the batching and mixing apparatus. The components of the non-Portland cementitious material may include brane fines of about 2500-5000 cm ² / g.

  In another embodiment, a system for applying a building material is provided. The system may include a batching and mixing device configured to batch process and mix blast furnace slag material, geopolymer material, alkaline powder, and sand to produce non-Portland cementitious material. The system may also include a conduit configured to transfer the non-Portland cementitious material from the batching and mixing device. In addition, the system receives the non-Portland cement based material and combines the transferred non-Portland cement based material with a liquid to produce a partially liquefied non-Portland cement based material It may also include a configured nozzle. The nozzle is further configured to apply the partially liquefied non-Portland cement-based material to a surface using air pressure.

One or more of the following features may be included. In some embodiments, the geopolymer material can be at least one of volcanic rock or pumice. The alkaline powder may include silicate. The step of mixing may be performed as dry mixing. The non-Portland cement based material may be inorganic. The mixing may be performed on a mobile batching and mixing vehicle. The non-Portland cement based material may include at least one of clay, gneiss, granite, quartz trachyte, andesite, piclite, potassium feldspar, albite, pumice, or zeolite. The mixing may include mixing with a portable gun configured to receive the non-Portland cement-based material from the batching and mixing apparatus. The components of the non-Portland cementitious material may include brane fines of about 2500-5000 cm ² / g.

  In another embodiment, a non-portland cement-based building material is provided. The non-portland cement-based building material may be blast furnace slag material, volcanic rock, alkaline powder, and sand. In some embodiments, the alkaline powder can be a silicate.

  The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the detailed description, the drawings, and the claims.

FIG. 1 is a side view of a transfer system configured to batch, mix and apply non-cement-based materials, according to an embodiment of the present disclosure. FIG. 1 is a rear side view of a transfer system configured to batch, mix, and apply non-cement-based materials, according to an embodiment of the present disclosure. FIG. 5 is a flow chart illustrating operations consistent with a non-cement based application process, according to embodiments of the present disclosure.

  Similar reference numbers in different drawings may indicate similar elements.

  Embodiments of the present disclosure relate to building materials having an alkali activated binder (i.e., non-portland cement systems), and systems and methods for their preparation and application. Although many of the examples contained herein are discussed in the context of concrete restoration, it should be noted that the building materials described herein may be used for any suitable application. Some of these may include, but are not limited to, sewer repair projects, concrete structures subject to acid attack.

  Referring to FIG. 1, a mobile batching and mixing vehicle 100 is shown having a number of containers, compartments, and devices associated therewith. In some embodiments, the vehicle 100 can include a first container 102 that can be configured to store sand or other material. Storage unit 104 may be configured to store water or other liquid. Vehicle 100 may further include batching and mixing device 106. Device 106 may include multiple parts, some of which may include, but are not limited to, the second container 108, the adjustable delivery mechanism 110, and the portable gun 212. As shown in FIG. 2, portable gun 212 may be connected to nozzle 214 via conduit or hose 216.

  In some embodiments, the mobile batching and mixing vehicle 100 may be configured to batch process, mix and apply non-Portland cement based building materials. This material may be batch processed and mixed prior to being placed in the vehicle (eg, in the batching and mixing device 106) or in the second container 108. This material can be transferred to the nozzle 214, where it can be mixed with the liquid from the storage unit 104 before being applied to the surface that needs construction or repair. The details of the non-portland cement-based building materials are described in more detail below in the text.

  In some embodiments, the non-Portland cementitious building materials described herein have higher strength values, higher resistance and resistance to inorganic and organic acids, and higher initial properties as compared to existing materials. It may have an intensity value. The material may comprise a dry mixture of blast furnace slag material, geopolymer material, alkaline powder, and sand, which may be mixed in a batching and mixing apparatus to produce non-portland cementitious material.

  In some embodiments, non-Portland cement-based construction materials can include various types of geopolymer materials. Some of these materials include, but are not limited to, pozzolanic materials. These materials react with strong alkalis and can also be mixed with sand (sand) and / or coarse sand (grit). In some embodiments, the pozzolanic material may comprise an activated silicate, such as slag sand or fly ash. Natural materials such as volcanic rock may also be used, in which case it may be desirable to use as a fine powder in lower proportions. The term "fly ash" as used herein may indicate non-natural pozzolanes.

In some embodiments, non-Portland cement-based construction materials can include any number of pozzolanic materials. Some of them may include finely divided clay, gneiss, granite, quartz trachyte, andesite, picrite, potassium feldspar, albite, pumice, zeolite etc, as well as mixtures thereof. Not limited to these. These materials can be used in calcined and / or uncalcined finely divided form. Additionally and / or alternatively, all the raw materials (ash, comprising a sufficient amount of reactive (eg metastable, glassy) silicon dioxide (SiO ₂ ) and aluminum oxide (Al ₂ O ₃ ) Pozzolas, including but not limited to slag, may also be suitable for the embodiments of the present disclosure.

  In some embodiments, non-Portland cement-based building materials can include alkaline-based powder materials, and / or various mixtures. Some possible mixtures may include, but are not limited to, potassium water glass and sodium water glass, alkali hydroxides, and the like.

  In some embodiments, the reaction between the silicon dioxide / aluminum oxide containing component and the alkali mixture can result in an aluminosilicate having a three dimensional structure. These skeletal structures allow the preparation of building materials that do not require Portland cement in the compound.

During operation, the raw materials may be fully batch processed and mixed (eg, in whole or in part at the vehicle 100) and then delivered to the portable gun 212. Non-Portland cement-based construction materials may be conveyed to the nozzle 214 via compressed air in the conduit 216. In a particular embodiment, potassium silicate (solid content 48%, density 1,52 g / cm ³ , SiO ₂ (dioxide) is used before the partially liquefied mixture can be applied pneumatically to the surface in question. Silicon): K ₂ O (potassium oxide) weight 1, 14) and certain liquids can be added in a short time (eg, less than 1 second) and thoroughly mixed in the nozzle 214.

Embodiments included herein may include mixtures that include some or all of the following materials. These materials may be slag (e.g. non-natural pozzolan, substrate), geopolymeric material (e.g. fly ash (e.g. non-natural pozzolan, optionally formulated), and / or natural pozzolan, and optionally Crushed volcanic rock material ) , alkali (eg, powder or liquid), other liquid including water (optional), and sand and / or coarse sand. Examples of specific mixtures are given below, but it should be noted that the specific mixtures presented herein are included by way of example only. Many additional additional alternative embodiments are also within the scope of the present disclosure.

表１ In a particular embodiment, the non-Portland cementitious building material may be comprised of the following mixture:

Table 1

In some embodiments, components of the mixture can have a brane fineness of about 2500-5000 cm ² / g.

表２ In another example, the non-portland cement-based building material may be comprised of the following mixture:

Table 2

表３ In another example, the non-portland cement-based building material may be comprised of the following mixture:

Table 3

The non-Portland cement-based building material embodiments produced unexpected results because the reaction time between the alkali component and the rock powder was sufficient to produce a sticky compound. Throughout all the tests, this compound was found to adhere very well to the vertical surface, build a tight bond and cure within 3 days at compressive strength values exceeding 50 N / mm ² (8000 psi) The

  The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the singular forms "one" ("a"), ("an") and "the" ("the") also include the plural, unless the context clearly indicates otherwise. It is intended. Also, the terms "comprises" and / or ("comprising"), as used herein, specify the presence of the recited features, integers, steps, operations, elements and / or parts. However, it will be appreciated that neither the presence nor the addition of one or more of the other features, integers, steps, operations, elements, parts and / or groups thereof are excluded.

  The corresponding structures, materials, acts and equivalents of all means or steps plus function elements in the following claims are to be carried out in combination with the elements of the other claims which are specifically claimed. It also includes the structure, material, or function of Although the description of the present disclosure is presented for purposes of illustration and description, it is not intended to be exhaustive or to limit the disclosure of the disclosed form. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. The embodiments are provided to best explain the principles and practical use of the present invention, as well as other embodiments with various modifications as would be appropriate to the particular application envisioned. It has been selected and described so that the present disclosure can be understood.

  While the disclosure of the present application has been described in detail and with reference to embodiments of the present invention, modifications and variations are possible without departing from the scope of the disclosure as defined in the appended claims. It will be clear that

DESCRIPTION OF SYMBOLS 100 Mobile batching and mixing vehicle 102 1st container 104 storage unit 106 batching and mixing apparatus 108 2nd container 110 adjustable delivery mechanism 212 portable gun 214 nozzle 216 conduit

Claims (7)

A method of applying building materials,
0.5 parts by mass to 1 part by mass of blast furnace slag material, 0.5 parts by mass or less of geopolymer material, 0.2 parts by mass to 2 parts by mass of alkali-based powder, and 1 part by mass to 1.35 parts by mass B. sand in a vehicle-related batching and mixing apparatus to produce a non-portland cement-based material , the geopolymer material comprising pozzolanic material ;
Transferring the non-Portland cement based material from the batching and mixing device to a portable gun configured to receive the non-Portland cement based material via a conduit, the portable gun being the vehicle Having a container configured to directly receive said non-Portland cementitious material from
Transferring the non-portland cementitious material from the container, via a hose, to a nozzle configured to be held by an operator;
Combining the transferred non-Portland cementitious material with a liquid at the nozzle to produce a partially liquefied non-Portland cementitious material;
Applying the partially liquefied non-portland cement-based material to a surface using air pressure using the nozzle;
The alkaline powder comprises a silicate,
Method.   The method of claim 1, wherein the geopolymer material comprises volcanic rock or pumice. Mixing by the batching and mixing apparatus is performed as a dry mixed-method of claim 1.   The method of claim 1, wherein the non-Portland cementitious material is inorganic.   The method according to claim 1, wherein the mixing is performed on a mobile vehicle comprising the batching and mixing device. The method of claim 1, wherein the geopolymer material comprises at least one of clay, gneiss, granite, quartz trachyte, andesite, picrite, potassium feldspar, albite, pumice, and zeolite. The method of claim 1, wherein the non-Portland cementitious material component has a brane fine value of 2500-5000 cm ² / g.

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